Stator of an electric motor and method of making same

Abstract

A stator of an electric motor having a stator core with a plurality of salient stator poles, an insulating cap, a stator winding consisting of a winding wire, and an interconnection unit with a plurality of winding-wire receptacles having an inside, wherein the winding wire is surrounded by a material constituting the winding-wire receptacle and connected and welded thereto on the inside. The stator is of an electric motor which is of a very high quality and precision so that high-current applications are possible. Without any major adjustments, the stator is combinable with different winding connections and is flexibly adaptable to the rest of the motor and possibly to the electronics design. The manufacturing method is capable of being flexibly adapted to different wire diameters.

What is claimed is: 
     
       1. A method for manufacturing a stator of an electric motor having a stator core with a plurality of salient stator poles, an insulating cap, a stator winding consisting of a winding wire, and an interconnection structure with a plurality of winding-wire receptacles, the method comprising the steps of:
 a) providing the stator core, the insulating cap, an end cap, the winding wire, a carrier unit and an interconnection unit or the interconnection structure with the carrier unit and the interconnection unit integrated together; 
 b) mounting the insulating cap and the end cap on in each case an axial end region of the stator core; 
 c) winding each of the plurality of salient stator poles of the stator core with the winding wire, wherein the winding wire is guided between two poles having a radial component beyond the diameter of the stator core and around a projecting arm and guided radially inwards angularly offset from a stator pole that is to be wound next while forming a conductor loop; 
 d) stripping winding wire regions of the conductor loop while holding in position and maintaining free accessibility by the projecting arm; 
 e) positionally mounting of the carrier unit and the interconnection unit or the interconnection structure with the carrier unit and interconnection unit integrated together, wherein the angular position of the winding-wire receptacles corresponds to the angular positions of the outwardly or inwardly running winding wire; 
 f) bending the conductor loop radially inwards with the aid of the carrier unit until the winding wire regions of the conductor loops engage in the winding-wire receptacle of the interconnection unit that is are bounded by contact fingers; 
 g) heating the contact fingers on both sides of the winding-wire receptacle before, after or during a cutting of the conductor loop by means of a laser beam until said contact fingers melt and the melted material internally connects with and welds to the winding wire; 
 h) removing one or more projecting arms either simultaneously or sequentially for temporarily supporting the conductor loop; and 
 i) mounting further components or assemblies. 
 
     
     
       2. The method according to  claim 1 , wherein the conductor loop is held radially inside and touching the winding-wire receptacle during the welding operation. 
     
     
       3. The method according to  claim 1 , wherein insulating rings are additionally provided, wherein after the mounting of a first interconnection unit, insulating rings and further interconnection units are alternately stacked on top of each other. 
     
     
       4. The method according to  claim 1 , wherein the carrier unit and a plurality of interconnection units are pre-assembled to form a single assembly. 
     
     
       5. The method according to  claim 4 , wherein the carrier unit and the plurality of interconnection units are encapsulated by injection molding in order to form an assembly. 
     
     
       6. The method according to  claim 4 , characterized in that the plurality of interconnection units are encapsulated by injection molding and the carrier unit is formed in this way.